Carding

Carding

Carding

The sayings of the specialists "The Card is the heart of the Spinning" and "Good Carded is half spun" show the enormous essentialness of checking for last consequence of the turning operation. - There is a solid relationship between increment underway and lessening in quality: the higher the execution, the most touchy turns into the checking operation and the more noteworthy the peril of a negative impact on quality. - The idea of checking the machine is unaltered since 1770. - Since 1965 creation rate has been expanded from around 5 Kg/h to around 100 Kg/h, a rate of expansion not coordinated by some other machine with the exception of the drawn outline.

Objects of the carding

- Opening the fibers into individual fibers, this empowers end of polluting influences and execution of different operations.

- End of impurities influences happens basically in the district of the taker-in. The level of cleaning attained to by current card is high, in the scope of 90 -95%. Consequently, the general level of cleaning attained to by the blow room and checking room together is as high as 95 -99%. Card fragment still contains 0.05 – 0.03% of the outside matter.

- End of Dust, which are certain to the filaments. Noteworthy fiber/metal and/or fiber/fiber erosion is required with a specific end goal to extricate such particles, this is accessible in checking operation.

- Unraveling of neps, The quantity of neps increments from machine to machine in the blow room, the card diminishes the staying number to a little part, they are basically opened out. Change in unraveling of neps is acquired by closer dispersing between dress; more honed attire; ideal velocity of taken; low doffer paces; lower throughput.

- Disposal of short filaments, this may happen at pads. Long strands have more contact with the dress of the primary barrel than the short filaments. Therefore, more filaments are constantly gotten and conveyed along the primary barrel, where the short strands stay discovered in the pads garments, press into it and leave the machine in the level stripping. The card dispenses with the little rate of short filaments around 1%.

- Fiber Mixing, transverse mixing happens in light of the fact that the card is the main machine to process singular filaments. In development, the web, and with rehashed pivot of the strands of the principle chamber, private fiber with fiber blending is accomplished.

- Fiber introduction: The card is regularly credited the impact of deadening. A parallel condition is accomplished on the fundamental barrel, however, it vanishes amid web arrangement in the middle of chamber and doffer.

- Bit development, for further transforming. By and large the hank lies somewhere around 4 and 5.5 Ktex in the short staple Spinning plan.

Cylinder Wire and Cylinder Speed
Cylinder wire determination is critical, it relies on cylinder speed, the raw material to be transformed and the creation rate. The accompanying qualities of cylinder wire ought to be considered.

Wire point
Tooth profundity
Wire populace
Rib thickness
Tooth profile
Tooth pitch
Tooth point

General wire stature of Carding 
Wire front point relies on upon primarily cylinder speed and coefficient of grating of raw material. Higher the cylinder speed, bring down the plot for a given fiber. The cylinder speed thusly relies on the creation rate. Higher creation implies additionally living up to expectations space for the fiber is needed. It is the wire that holds the fiber under its impact during checking operation. Consequently the space inside the wire ought to additionally be more for higher creation. Higher cylinder speed likewise expands the space for the fiber. Thusly higher cylinder speed is needed for higher creation. On account of high creation checking machines, the cylinder surface is all that much higher, along these lines even with higher number of fibers bolstered to the cylinder, the cylinder is replenishing the checking surface at a speedier rate.

Higher the cylinder speed, higher the divergent power made by the cylinder, this tries to discharge the fiber from the cylinder, alongside the waste. It is the cylinder wire's front edge which conquers the impact of this power. Low front edge with too low cylinder speed and with high frictional power will bring about terrible quality, in light of the fact that the fiber exchanges from cylinder to doffer will be less. Thus reusing of fibers will happen, which bring about more neps and traps. The new profile with less free blade abstains from stacking of the cylinder with fiber and/or rubbish. This aides in keeping the fibers at the tip of the tooth. The development of the fibers towards the tip of the tooth coupled with diffusive activity requests an intense front edge to hold the fiber in place during checking. Absence of solidness connected with fine and/or long fibers requires more control during the checking procedure. This control is gotten by selecting the tooth pitch, which gives the right proportion of the quantity of teeth to the fiber length. Tooth pitch decrease is in this way needed for astoundingly short fibers and those need solidness. Number of focuses across the checking machine is chosen by the rib width. It is chosen in light of the generation rate and fiber measurements. Better the fiber, better the rib width. The pattern is to better rib width for higher generation.

The number of inhabitants in a wire is the result of the rib thickness and tooth pitch. The general tenet is higher populaces for higher generation rates, yet it relies on the application. Sharp tooth focuses penetrate the fiber all the more effortlessly and help to heighten the checking activity. Cut-to-point wires are sharp and they have no area by any stretch of the imagination. The successful working profundity of a cylinder wire tooth for cotton is roughly 0.2mm and for manufactured materials approx.0.4mm. Artificial fibers oblige more space in their cylinder wire than doe's cotton. More tooth profundity permits the fiber to recycled, bringing about harmed fibers and neps. On the off chance that tooth profundity is lacking, there will be loss of fiber control. This will bring about much more noteworthy nep era. Investigating the above subtle elements, the accompanying determinations can be utilized as a guideline.

DOFFER, LICKER-IN AND FLAT TOPS
The fundamental capacity of doffer is to strip the fibers from Cylinder. If you don't mind recall that the activity in the middle of cylinder and doffer is checking activity (or combing activity or point to point activity).

The doffer wire's front edge assumes an essential part in discharging the fiber from the cylinder. For most checking applications the ideal edge is 60 degrees.

Expanded populace more than 400 ppsi does not give any preference in the generation of quality yarn. For littler doffers, 5 mm doffer wire tallness helps in transferring the fibers from cylinder to doffer.

In the event that the fiber holding limit of the doffer wire is less because of fiber grinding or because of high doffer speed, it is ideal to utilize a doffer wire with striations. For high creation checking itis constantly better to utilize doffer wire with striations.

Licker-in assumes a significant part in opening the fiber tufts. All in all 85 degrees is utilized both for engineered and medium and long cottons. For coarse and grimy cottons 80 degrees can be utilized.

Quality, hardness and sharpness are essential for Lickerin wire. Licker-in wires ought to never be ground. More slender blades penetrate the fibers all the more productively and expand the wire life.

Higher number of columns every inch gives better results. Presently up to 12 lines every inch is being utilized. This is constantly better contrasted with 8 lines every inch.

On the off chance that the wire pitch is not adequate, it can be repaid by expanding the licker-in speed. Higher licker-in speeds for fine and long cottons will burst the fibers. Licker-in speed relies on the fiber sort and the generation rate.

It is ideal to utilize a flat top with more than one populace. The general combination is 280/450. This is suitable for both cotton and synthetics. If you don't mind recollect that the inflexibility of the filets is distinctive for cotton and engineered. In the event that cotton flat tops are utilized for engineered handling, the heap on the cylinder will be all the more, more warmth will be delivered and subsequently the likelihood of cylinder stacking because of electrostatic charge will be high.

As opposed to utilizing Rigid sort flat tops, it is ideal to utilize semirigid sort flat tops while transforming engineered fibers.

SETTINGS: 
The setting in the middle of cylinder and doffer is the nearest setting in the card. This setting predominantly relies on the cylinder speed, hank of the conveyed bit and the sort of wire. Cylinder speed up to 360, the setting ought to be 0.1mm. For cylinder speeds more than 450, the setting extents from 0.125 to 0.15.

In the event that the setting in the middle of cylinder and doffer is close, the wires will get cleaned and this will influence the fiber exchange. In the event that the setting is too wide, the fibers won't be exchanged to doffer from the cylinder, henceforth cylinder will get stacked. While transforming engineered fibers cylinder stacking will severely influence the yarn quality. Also, it is hard to enhance the wire condition if the stacking is extreme. The main arrangement would be to change the wire. In this sufficiently manner consideration ought to be taken while transforming engineered fibers.

The most discriminating setting in a checking machine is in the middle of cylinder and flat tops. While preparing cotton, it can be as close as 0.175 mm gave the mechanical precision of flat tops is great. Since a large portion of the cards are with stationary flats at the licker-in side, the setting from the back to front for flats can be 0.25, 0.2.0.2, 0.2, 0.2mm.

Closer the setting in the middle of cylinder and flats, better the yarn quality. Neps are straightforwardly influenced by this setting. Obviously, close setting expand the flat waste. For preparing cotton the setting can be 0.25, 0.2, 0.2, 0.2, 0.2mm. For engineered fibers it can be 0.3, 0.25, 0.25, 0.25, 0.25mm

The vast majority of the cards are with 6 to 1 stationary flats at the licker-in side. This setting can begin with 0.4 mm and end with 0.25mm.

The wire focuses can begin with 140 ppsi and end with 320 ppsi. The work done by the initial couple of stationary flats is high; in this way the wear of these flats is likewise high. It would be better if the initial 50% of the flats are changed after 100000 kgs of creation and the rest after 150000 kgs of generation.

These stationary flats open the material so that, the setting in the middle of cylinder and flats can be as close as would be prudent.

The setting between food plate and Licker-in relies on the kind of food plate. Traditional food plate setting is chosen primarily by the food weight and to some degree by the fiber length and sort. With the most recent food plate and food roller game plans, the setting is chosen mostly by the fiber length and to some degree by the food weight.

Typically the setting between the food plate and Lickr-in is around 0.45 to 0.7mm, contingent on the food weight and fiber sort.

The setting between Licker-in and the first bit blade is around 0.35 to 0.5 mm. This serves to uproot the heavier refuse particles and dust. Closer the setting, higher the wastage. The setting between Licker-in and combing fragments is around 0.45 to 0.6. This serves to open the material.

A few cards have two bit knifes in the Licker-in under packaging. The setting is around 0.4 to 0.5mm. This serves to uproot the littler junk and dust particles.

The setting between the cylinder and stationary flats at Doffer side serves to exchange the fibers to doffer by stripping the fibers to the highest point of the cylinder wire. This setting can be as close as 0.15mm. The quantity of wire focuses on stationary flats likewise assumes a real part. It is typically around 300 to 400. For a high generation application it can be as high as 600.

For cotton transforming, the stationary flats are altered with a blade connection. The setting ought to be as close as could be expected under the circumstances, i.e. around 0.15mm. This serves to uproot the waste particles of little size.

The setting in the middle of cylinder and cylinder under packaging ought to be according to the manufacturer's proposal. The configuration of under packaging is diverse for distinctive manufacturers. This setting is critical, as wrong settings will influence the fiber exchange and can likewise make air turbulence.

SPEEDS: 
Higher cylinder speed helps fiber exchange. Higher the generation, higher ought to be the cylinder speed.
Higher cylinder speed enhances checking activity, in this way blemishes are lessened.
Higher Licker-in speed for coarse fibers and filthy cotton serves to evacuate the garbage and enhances, the yarn quality. For fine and long cottons, higher speed results in fiber burst, accordingly, flat waste and comber noil will be more.
Higher flat speed, enhances yarn quality and in the meantime builds the flat waste.
With the same flat speed, higher the checking creation, bring down the flat waste and the other way around.
High strain drafts will influence checking U%. It is ideal to keep the draft between food rollers to doffer around 75 to 95. The outcomes are discovered better with these drafts.

WIRE MAINTENANCE IN CARD
For a modern cylinder wire of 2mm tallness, pounding with the ordinary crushing stone is not suggested. It is ideal to utilize TSG processor to crush the wire each 2nd or 3rd month, so that the sharpness of the wire is constantly kept up.

TSG processor does not pound the wire, thusly if the wire is exhausted seriously the quality change utilizing this pounding machine will be nil. Incessant grindings are prescribed. In the event that TSG processor is not accessible, it is better not to granulate 2mm wires.

The quantity of navigate ought to expand relying on the life of the wire. The quantity of cross for progressive grindings ought to be similar to this 3, 5, 10, 17 and so forth. In any case the best strategy is to affirm with the magnifying instrument. On the off chance that the crushing is not adequate, the quantity of navigate ought to be expanded.

Doffer is as yet meeting expectations with an idea of Land arrangement. A typical crushing machine will be useful for doffer granulating. All the wire focuses ought to be touched by the pounding stone. A moderate and progressive pounding with the toil out idea will give the best results. Unforgiving grindings will bring about burr arrangement on the area. This will expand the quantity of hooks in the fiber; consequently the successful length of the fiber from this card will be lessened.

Flat tops granulating is vital. Each time a flat top is ground, yarn quality is moved forward. It is ideal to utilize a crushing machine with the emery filet. Successive flat tops granulating will bring about less neps and the yarn quality will be reliable.

A few factories expand the life of the flat tops contrasted with cylinder wire. However, it is ideal to change flat tops and cylinder wire together for better and predictable yarn quality.

It is a decent practice to check the individual card quality before changing the wire.

Licker-in wire ought to be changed for each 150000 kgs. Prior changes will further enhance the yarn quality.

Stationary flats ought to be changed for each 150000 kgs. Be that as it may, it is a decent practice to change the initial 3 or 6 stationary flats at Licker-in side for each 100000 kgs. This serves to boost the checking impact in the middle of cylinder and doffer which is basic for better yarn quality.